Covered cart assembly and methods of assembling and making the assembly

ABSTRACT

A cart assembly has canvas top and side walls for transporting products on a base platform carried on wheels. Inversely U-shaped front and rear side rail skeleton structures, with vertically spaced cross rails, on the cart define a product compartment between them. Vertically spaced side straps loop around the side rail structures to correlate with the cross rails and have coupler ends. A unitary fabric cover is draped in inversely U-shaped configuration on the cart to provide a top wall and side walls. Cover straps carrying mating couplers project from the side walls of the cover in vertically spaced relation correlating with the cross rails to couple with the couplers on the side straps.

The application claims the priority of provisional patent application Serial No. 60/315,561, filed Aug. 29, 2001.

This invention relates generally to the manufacture and assembly of covered carts for transporting products of varying description.

BACKGROUND OF THE INVENTION

Presently, castered carts are known for transporting diverse products such as stacked cases of beverage containers or cartons, for example, from manufacturing or distribution centers to trucks which move them to other facilities such as retailing facilities. Such carts normally have skeletal front and rear end frames extending upwardly from a base platform but are otherwise open to the elements. In the past, closures or tarps of canvas or like material, have been used to enclose the load and protect it from the elements. The tarp was however not, to our knowledge, integrated with the cart end walls in the manner to be described to function as top and side walls in a manner to efficiently mitigate load shifting.

SUMMARY OF THE INVENTION

A transport delivery system assembly according to the present invention employs a flexible tarp cover, draped in inversely U-shaped configuration, to cover the load. The flexible and pliant cover integrates with the cart front and rear end rail structures, which include side rails and have a plurality of vertically spaced cross braces, in a manner so that the tarp cover effectively provides the top and side walls of the cart. Strap mounted coupler parts projecting at spaced intervals from the front and rear edges of the tarp disengageably couple with mating coupler parts provided on straps which are looped around the end rail structures and bear upon the cross braces to support the weight of the tarp.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein:

FIG. 1 is a schematic perspective front elevational view of a typical cart with the cart tarp or cover secured in position, the stacked products normally carried on the cart when the tarp is in secured position being omitted from the view in the interest of clarity;

FIG. 2 is an enlarged, partly sectional, schematic, front elevational view with certain parts being omitted;

FIG. 3 is an enlarged schematic fragmentary top plan view of typical coupler elements in disengaged position; and

FIG. 4 is a considerably enlarged schematic fragmentary top plan view of the free end of a strap securing to the top rail portion of the cart extending through its strap coupler part.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now more particularly to the accompanying drawings and in the first instance to FIGS. 1 and 2 particularly, a typical cart is shown as having a base or platform 10 supported on front castered wheels 11 and rear castered wheels 12 which are carried on caster frames 11 a and 12 a. Intermediately, brackets 13 depend from the base platform 10 to support a dead axle 14 on which noncastered wheels 15 are received. Provided in the base platform 10 at its corners are sockets 16 for snugly receiving the free lower ends of the side rail portions 17 of front and rear inversely U-shaped front and rear end rail structures generally designated 18 and 19 respectively. The rail sections 17 may have the cross-sectional configuration of the side rails of the hand truck disclosed in the present assignee's U.S. Pat. Nos. 4,762,333 or 5,393,081, and the sockets 16 are of a mating configuration. Rail structures 18 and 19 each include the side rail portions 17, top rail portions 20, and vertically spaced cross braces 21 which fixedly bolt or otherwise secure to the side rail portions 17.

A tarp or cover, generally designated T, is provided to form the top and side walls of the cart when the cart is in transport condition. Typically, the tarp T may be formed of a woven synthetic plastic fabric such as a polyvinyl chloride canvas or other suitable cover. It is used in inversely U-shaped configuration, draped over the load to be carried, in the manner indicated in FIG. 1, and supported by the end rail structures 18 and 19. The tarp T is secured in a manner to prevent load shifting and provides load enclosing side and top walls 22 and 23 respectively. Preferably, the one piece tarp material will be opaque and fashioned of a relatively heavy gauge material.

As FIG. 1 particularly shows, fabric reinforcing webbing or straps extend at spaced intervals as at 24 from the front edge of the tarp T to the rear edge thereof and project a given distance forwardly and rearwardly therefrom. These ends of the straps 24 then loop around the integrated eye or ring portions 25 (FIG. 3) provided on socket coupler parts generally designated 26 and return to be sewn or secured to the body of the straps 24 as at 24 a. The socket coupler elements 26 are part of an overall conventional coupler assembly, generally designated C, which includes the usual male coupler fitting or part or portion generally designated 27 which has projecting resilient lock detents or prongs 27 a which are cammed inwardly as they are received within the socket coupler part 26. The part 27 also includes the guide part 27 b which cooperates with guide surfaces within socket part 26.

The coupler system C may comprise the well known Velcro 500 fastener system wherein the spring legs or detents 27 a are forced inwardly when moved into the socket 26 and then are permitted to spring outwardly through locking openings 26 a in the sides of the socket part 26 to releasably lock in position. In coupling systems of this character, the middle member 27 b is simply a guide member and the spring legs or detents 27 a, which have the locking shoulders 27 c locking on the front edges of openings 26 a, are released when they are grasped and pressed laterally inwardly into the openings 26 a. Other similar coupler systems may be utilized as well as the Velcro 500 system manufactured by Velcro U.S.A. Incorporated in the United States.

Coupler system straps or belts 28 are secured around the buckle eyes generally designated 27 d of the male couplers 27 and, as FIGS. 1 and 2 indicate, loop around the front and back rail structures 18 and 19. The free ends 28 a of straps 28 then return to the coupler buckle eyes or parts 27 d of the male couplers 27, passing in under the buckle eye bar 27 e thereof so as to be engaged by the projecting teeth 27 f which may be provided thereon. With the teeth 27 f releasably preventing withdrawal from the eyes 27 d, the free end 28 a of each coupler or strap 28 can be pulled through a coupler buckle eye 27 d to a tightened or taut position and the free end of the tightened strap 28 will then be releasably held in place by the coupler teeth 27 f. As indicated, the coupler system employed may be any one of a number of conventional systems such as the similar YKK System, and even ordinary belt buckles, for example, could conceivably be employed. Because of the coupler parts 26 and 27, the straps 28 can remain in position looped around the side rail portions 17 and top rail portions 20 of the front and rear rail structures 18 and 19, unless the tarp T is to be completely disengaged.

The Operation

Normally, to load the cart, only one side portion 22 of the tarp may be disengaged by disconnecting its coupler parts 26 and 27, and simply lifting it upwardly and depositing it over the top rail portions 20 to drape upon the opposite engaged side portion 22. Then, loading of the platform 10 can take place, and when this has been accomplished, the freed side wall 22 may be brought down into position once again and the male and female couplers 26 and 27 reengaged. The weight of the tarp T, which may be in the neighborhood of 9 pounds, for example, bears down on the cross rails 21 to restrain the load shifting which normally commences at the upper end of a stack of products. With this structure, the weight also does not stress the couplers C, and this enables ready disengagement of the couplers C and does not impose forces upon them which would tend to shorten their service lives.

The enclosed embodiment is representative of a presently preferred form of the invention, but is intended to be illustrative rather than definitive thereof. The invention is defined in the claims. 

We claim:
 1. A merchandise cart assembly with canvas top and side walls for transporting products including: a. a cart comprising an elongate base platform carried on wheels including pairs of front and rear end wheels; b. inversely U-shaped front and rear side rail structures with skeleton top rail portions and side rail portions, fixedly secured to the front end of the platform and to the rear end of the platform, and partially defining a product carrying compartment between them; c. said front and rear rail structures having vertically spaced cross rails spanning said side rail portions; d. vertically spaced apart side straps looped around the side rail structures, said straps being spaced apart to correlate with said cross rails and lie upon and be vertically supported by said cross rails and having free ends with couplers thereon; e. a unitary flexible fabric cover secured to said rail structures draped in inversely U-shaped configuration to provide a top wall extending between said top rail portions of said front and rear rail structures, and side walls extending between said front and rear rail structures; and f. mating cover straps carrying mating couplers secured to project from said side walls of said cover in vertically spaced relation correlating with said cross rails to couple with said couplers on said side straps.
 2. The cart assembly of claim 1 wherein said top wall of said cover has at least one top cover strap secured to project from said top wall of the cover at each end of the cover and said top rail portions of said rail structures have mating straps looped around said top rail portions in alignment to couple with said top cover strap, and coupler parts are provided for coupling said top cover strap on said cover and top rail straps on said top rail portions.
 3. The cart assembly of claim 1 wherein strap retention mechanism is provided on said straps to facilitate drawing said couplers back to tauten said straps and releasably retain them in position.
 4. The cart assembly of claim 1 wherein male and female couplers are provided on the ends of said side straps and their mating cover straps, and one of said straps of each mating pair of straps on said cover and side rail structure has a tautening mechanism for taking up any slack.
 5. The cart assembly of claim 1 wherein said cover straps are formed by unitary strap members extending from one end of said cover to the other and projecting beyond said cover at each end thereof.
 6. A covered merchandise cart assembly for transporting products including: a. a cart comprising an elongate base platform carried on front and rear end wheels including castered wheels; b. inversely U-shaped front and rear rail structures with top rail portions and side rail portions fixedly secured to the front end of the platform and to the rear end of the platform, and defining a product carrying compartment between them; c. cross rails spanning said side rail portions of the front and rear rails; d. vertically spaced apart side straps looped around said side rail portions above said cross rails, said straps being spaced apart to lie upon and be vertically supported by said cross rails and having free ends with couplers thereon; e. a unitary flexible fabric cover secured to said rail structures draped in inversely U-shaped configuration to provide a top wall extending between said top rail portions of said front and rear rail structures, and side walls extending between said front and rear rail structures; and f. cover straps carrying mating couplers secured to project from said side walls of said cover in spaced relation correlating with said cross rails to couple with said couplers on said straps looped around said side rail portions.
 7. The cart assembly of claim 6 wherein said cover straps are formed by unitary strap members extending from one edge of said cover to the other and projecting beyond said cover at each said edge thereof.
 8. The cart assembly of claim 6 wherein said top wall of said cover has at least one top cover strap secured to project from said top wall of the cover at each end of the cover and said top rail portions of said rail structures have mating straps looped around said top rail portions in alignment to couple with said top cover strap, and coupler parts are provided for coupling said top cover strap on said cover and top rail straps on said top rail portions.
 9. The cart assembly of claim 6 wherein male and female couplers are provided on the ends of said side straps and their mating cover straps, and one of said straps of each mating pair of straps on said cover and side rail structure has a tautening mechanism for taking up any slack.
 10. A method of assembling a merchandise cart assembly with canvas top and side walls for transporting products including: a. providing a base platform carried on wheels; b. providing inversely U-shaped front and rear side rail structures with skeleton top rail portions and side rail portions, fixedly secured to the front end of the platform and to the rear end of the platform, and defining a product carrying space between them; c. said front and rear rail structures having vertically spaced cross rails spanning said side rail portions; d. looping vertically spaced apart side straps around the side rail structures to correlate with said cross rails and lie upon and be vertically supported by said cross rails and having free ends with couplers thereon; e. draping a unitary flexible fabric cover in inversely U-shaped configuration on said cart to provide a top wall and side walls extending between said front and rear rail structures while securing cover straps, carrying mating couplers, projecting from said side walls of said cover in vertically spaced relation correlating with said cross rails, to said couplers on said side straps.
 11. The method of claim 10 comprising providing strap retention mechanism on said straps to facilitate drawing said couplers back to tauten said straps and releasably retain them in position.
 12. The method of claim 10 comprising providing said couplers as male and female couplers on the ends of said side straps and their mating cover straps, and providing one of said straps of each mating pair of straps on said cover and side rail structure with a tautening mechanism for taking up slack.
 13. The method of claim 10 comprising providing said top wall of said cover with at least one top cover strap secured to project from said top wall of the cover at each end of the cover and providing said top rail portions of said rail structures with mating straps looped around said top rail portions to couple with said top cover straps, and providing coupler parts for coupling said top straps on said cover and top rail straps on said top rail portions.
 14. The method of claim 10 comprising providing bottom side straps with couplers thereon looped around the lower ends of said side rail portions and providing mating straps on the cover lower edge portions having couplers for coupling to said bottom side strap couplers.
 15. A tarp device for use with a merchandise cart assembly to provide canvas top and side walls for a cart assembly which includes a base platform carried on wheels, including front and rear end wheels; inversely U-shaped front and rear side rail structures with skeleton top rail portions and side rail portions, fixedly secured to the front end of the platform and to the rear end of the platform, and defining a product carrying compartment between them; said front and rear rail structures having vertically spaced cross rails spanning said side rail portions, said tarp device including: a. vertically spaced apart side straps to be looped around said side rail structures, said straps being spaced apart to correlate with said cross rails and lie upon and be vertically supported by said cross rails and having free ends with couplers thereon; b. a unitary flexible fabric cover adapted to be secured to said rail structures and draped in inversely U-shaped configuration to provide a top wall extending between said top rail portions of said front and rear rail structures, and side walls extending between said front and rear rail structures; and c. mating cover straps carrying mating couplers secured to project from said side walls of said cover in vertically spaced relation correlating with said cross rails to couple with said couplers on said side straps.
 16. The tarp device of claim 15 wherein said top wall of said cover has at least one top cover strap secured to project from said top wall of the cover at each end of the cover and mating straps for looping around said top rail portions in alignment to couple with said top cover straps, and coupler parts are provided for coupling said top straps on said cover and top rail straps on said top rail portions.
 17. The tarp device of claim 15 wherein strap retention mechanism is provided on said straps to facilitate drawing said couplers back to tauten said straps and releasably retain them in position.
 18. The tarp device of claim 15 wherein male and female couplers are provided on the ends of said side straps and their mating cover straps, and one of said straps of each mating pair of straps on said cover and side rail structure has a tautening mechanism for taking up any slack.
 19. The tarp device of claim 15 wherein said cover straps are formed by unitary strap members extending from one end of said cover to the other and projecting beyond said cover at each end thereof. 